ML19207C113

QC Procedure QCP-M-012 for Final Acceptance Insp

ML19207C113
Person / Time
Site:	Crane
Issue date:	05/04/1979
From:	Hoffer G, Wright G GENERAL PUBLIC UTILITIES CORP., METROPOLITAN EDISON CO.
To:
References
QCP-M-012, QCP-M-12, NUDOCS 7909060454
Download: ML19207C113 (19)

Text

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Attached please find a copy of the subj ect procedure for your immediate Please sign the bottom portion of this transmittal indicating re-use.

ceipt of the new revision; detach it, and return it to us together with the old revision.

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GPUSC QA Engineer From:

To: GPUSC QA

Subject:

Receipt of Procedure QC.P(4.C Q Rev. No.

C Attached please find our copy of the old revision of the subject procedure.

We will use the new revision as of (DATE)

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Rev. 0 Date: May 4,1979 QPU SERVICE CORPORATION QUALITY CONTROL PROCEDURE QCP-M-012 FOR FINAL ACCEPTANCE INSPECTION THREE MILE ISLA.ND - UNIT 2 (MODIFICATION) u[N CONCURRED BY:

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Rev. O Date: May 4, 1979 GPU SERVICE CORPORATION QUALITY CONTROL PROCEDURE QCP-M-012 FOR FINAL ACCEPTANCE INSPECTION I.

SCOPE This procedure is applicabe to nuclear and nuclear safety related systems and structures, part of the TMI-2 Modifications Program.

Thisprocedureshallbeusedduringpre-operationalcheckouts, through ce=pletion of the modification, including checks for func-tional or. operational tests. Modification related checks include hydrostatic tests, flushing, meggering, continuity checks, and mo-tor starting-tests, and all items identified in the proce :ure for testing, e.nd checks of mechanical and electrical equipment.

II.

GENERA L A.

Purpose The purpose of this procedure is to outline the method for determining the Quality status,and acceptance of cc=pleted modifications to systems, sub-systems, components and struc-tures, part of the TMI-2 Modifications Program.

B.

Reference Documents v

The requirements of all applicable GPUSC QC procedures and the following reference documents shall apply to all items covered within the scope of this document.

1. Engineer Specifications (BGR)

2. Test Procedures

3. Test Instructions

4. ANSI N45.26 - Qualification of Inspection G Test Personnel.

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QCP-M-012 Rev. O Date:May 4, 1979 II.

GENERAL - Continued C.

Check Lists, The reference to check lists (A ttachment "A") in this pro-

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cedure shall apply to a written list of the requirements specified by drawings, equipment manuals, system specifica-tions, vendor installation procedures and operating canuals, and other instructions that must be complied with to assure the integrity and quality of materials and work =anship of the equip =ent, system, and/or sub-syste= being inspected for final acceptance.

D.

Final Accentance Inspection Descriotion Final acceptance inspection shall be conducted as follows:

1.

Final Inspection - A visual inspection of the co=pleted system, or part thereof, and review of quality ass tance docu=entation *

..ssure that all requirec work and docunentation is satisfactorily cc=pleted, and that this syste=, sub-system, or structure is ready for turnover to Met-Ed QC and Met-Ed/GPU Start-Up.

E.

De finitions Verify:

- as used in this procedure requires that a Quality Control spector will observe and assure that the work accomplished on equipment within the scope of this docunent is in accordance with specifications and procedures.

III.

RESPONSIBILITY The sequence and schedule of final inspection shall be coordinated by the GPUSC Lead Quality Control Engineer and the Craft Supervisors of the applicable contractors upon notice of scheduled cc=pletion of the construction activity.

Met-Ed/GPU Start-Up is responsible for providing the Lead Quality Control Engineer with advance notice of test schedules, n q It>M v.s..G(u s 2 -

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QCP-M-012 Rev. O Date: May 4,1979 IV.

PROCEDURE A.

Scheduling of Final Acceptance Inspection Schedules for final acceptance inspection shall be based on the following:

1. Scheduled completion of work by the contractor as defined in the specification,. work order, contract, or pur-chase order.

2. Scheduled completion of work as reported by the Craft Sup-ervisor, Job Engineer, or Proj ect Superint endent.

3. Scheduled completion of pre-operational check-nspec-tion and/or turn over for functional testing.

Note: Checks which require verification by Quality Control, but were conducted without Quality Control participa-tion, shall be rescheduled and re-run.

B.

Preparation of Check Lists

1. Prior to scheduled final acceptance inspection the Quality Control Engineer will prepare a check list fo use during the inspection (see sample format - Attachme nt "A").

Gen-eral type check lists may be prepar ed for final inspection 7

of similar systems components or sub-syste=s, however, unique or special situations which are not covered by gen-eral check lists will require preparation of a special check list before final inspection is scheduled.

2. The check lists referenced herein require review and approval by the Lead Quality Control Engineer. After his

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QCP-M-012 Rev. O Date: May 4, 1979 IV.

PROCEDURE - Canunued B.

2. - Continued approval is given, the check lists are submitted to the GPUSC Site QA Manager for final approval, prior to use.

Quality Control shall furnish the cognizant Craft Super-visor with a copy of the approved check list prior to performing the inspection.

Items to be considered for check points include the following:

a. Verification of available documentation for materials, in-process inspection, tests, welding, (Vendor docu-mentation as well as on-site documentation) Tie-In Authorization form, etc.

b. Verification of compliance with applicable revision of drawings,, specifications, procedures, and 36R opera-tions procedures.

c. Visual inspection to verify satisfactory completion of work.

d. Verification that either all Deviation Reports S Holo Tags have been cleared and that there are no outstanding items, or they are documented on a punch list.

e. Verifi ation of cleanliness levels as specified by Engineering Specification.

f. Verification that any teqporary installations, connect-tions, or disassembly has been restored to design re-quirements.

g. Verification of required identification and markings.

h. Verification of the physical integrity, i.e., lack-of-damage.

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Rev. O Date:May 4, 1979 IV.

PROCEDURE - Continued B.

2. - Continued

i. - Continuci Items ident.iicd as requiring QC checks in the applicable test procedure,

j. System description developed and distributed.

k. Operating proc.dures developed and distributed.

1. Check point items that are rejected or declared not applicable and are marked JA, require explanation in the remarks section of the check list.

3. The. heck lists may be supplemented by QC records of tests such as the Leak Test Report prepared for hyrostatic tests and the Inspection Report prepared for final flushing.

C.

Final Acceptance Inspection

1. Prior to scheduling final inspection:

The cognizant Craft Supervisor will perform the neces-a.

sary checks and, final inspection of the turnover ite=s to assure all required work or tests have been completed.

b. The checks and inspection of the designated work shall be riocumented by the cognizant supervisor certifying cocple-tion of construction and transmitted to the Lead Mechanical QC Engineer. This will include a co=plete list of turnover ite=s, marked up drawing or other sketch which will clearly identify the insp ection boundary.

2. Inspector (s) from the Quality Control Group will be assigned by the Lead Quality Control Engineer to inspect the designated work. Quality Control will then schedule and initiate the final inspection using the applicable ap-proved check list (s).

In situations where Quality Control has advance information from,the Craft Supervisor that a system /sub-system is bgingg,

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Rev. O Date: May 4,1979 IV.

PROCEDURE - Continued C.

Final Acceptance Inspection - Continued

2. - Continued checked for completion and will be submitted for final inspection, the Lead Quality Control Engineer may direct the Quality Control Inspector to prepare for turnover the anticipated inspection by: performing pre-liminary inspections, familiarizing himself with the sys-tem equipment, assembling records for the data package, check for incomplete. work, review records to assure there are no outstanding Deviation Reports and other actions that can be perforced expediently in advance of the sched-uled final inspection.

3. Final Inspection consists of:

a. Visual inspection of completed work

.d other inspec-tion requirements as specified by the applicable check list.

b. Review of Quality Assurance Records to assure documents are complete and adequate for the completed work.

c. Review of Quality Control records to assure that re-quired construction related inspections have been com-pleted and docu=ented. A list of all Deviation Reports and Nonconforming Inspection Reports shall be developed, and those which are not cle.sred shall be listed on the Quality Control Final Acceptance Punch List (Attachment "B"). When a nonconforming report is listed as a punch list item, the Quality Control Engineer shall note on the original report the turnover packsge name/nu=ber and the punch list item number and include this report in the package. 31SOf 6 For closed NCR's/DR's, the list shall indicate the

' number of the Inspection Report that closed them out.

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QCP-M-012 R sv. O Date: May 4, 1979 IV.

PROCEDURE - Continued C.

Final Acceptance Inspection - Continued

3. - Continued

d. Co=plete check list (s) and Quality Control Final Acceptance Punch list (Attachment "B") and asse=ble together with the docu=entation and boundary identifi-cation provided by the Craft Supervisor for turnover package.

e. Mark-up of system, isometric, etc., by the QC Engineer to show status of inspection of the system. This status shall be maintained current by Quality Control.

f. Co=plete Quality Control portion of the Turnover Agreement (Attach =ent "C") for turnover to Met-Ed/GPU Start-Up and Met-Ed QC.

g.' The Turnaver Agreement shall be transmitted to the assigned QA Engineer for auditing using Attach =ent "F" which will bece=e a per=anent part of the agreement.

If the audit results in any co==ents and/or discrepancies, they shall be identified on Attach =ent "F" and the agree =ent returned to Quality Control for resolution.

When all co==ents and/or di'screpancies are resolved to the satisfaction of QA, Attachment "F" will then be signed in the applicable area,

h. Af ter QC and Start-Up acceptance of the turnover agreement, the system boundaries will be tagged by the Start-Up Depart =ent to show the portion of the system under Start-Up control.

4. The inspector should give particula. attention to co=pleting the check list to assure that the nature and location of r

punch list items and incomplete and temporary items are adequately described in the inspection check list. Entries must be clearly stated for subsequent use of the check list by the Lead Start-Up Quality Control Engineer, craft, and Start-Up personnel.

5. The Lead Quality Control Engineer or his designate shall

, review the co=pleted Tun 2over Agreement (Attach =ent "F"),

checklist, and any deviation, punch list iter. or inco=plete or temporary items that may have been docu=ented and take the following action:..

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QCP-M-012 Rev. O Date: May 4, 1979 IV.

PROCEDURE - Continued C.

Final Acceptance Inspection - Continued

5. - Continued

a. Review the checklist and assure that all outstanding punch list item.n and incomplete or te=porary items are identified in the appropriate section. Disposition of processed in accordance with deviations shall 2

Paragraph IV.D. below.

Incomplete items unacceptable for turnover shall be returned by Quality Control to the responsible craft supervisor and docu=ented on Equipment Turnback Sheet (Attachment "D").

The reason for turnback shall_ be clearly identified on the Turn-back Sheet.

b. Establish that Final Acceptance Inspection has been co=pleted.

c. Authorize turnover of the systec, sub-system, or equipment using the Turnover" Agreement (Attachment "C").

6. The Lead Quality Control Engineer shall maintain system sketches marked-up to show inspected systems and sub-systems.

Revisions made to drawings of turned over syste=s shall be shown by mark up of the turnover status drawings maintained by QC or the revised drawing may be marked up to show the status of turnover.

D.

Discosition of Reoorted Deviations

1. All non-confor=ing items disclosed in the Final Acceptance,

Inspections must be dispositioned per QCP-M-004 and corrected by the responsible contractor, subcontractor, or craft activity.

Inco=plete work items listed on final inspection check lists which are scheduled for future conpletion to specification requirements need not be handled per QCP-M-004.

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QCP-M-012 Rev. O Date: May 4, 1979 V.

REWORK, REPAIR OR NODIFICATION A.

The status of final acceptance inspection of equipment /

systems / portions of syste=s shall be negated when craf ts or contractor personnel perform repair, rework, or make modifications.

The exception is when the contractor is perfor=ing work to resolve punch list items or responding to approved design changes.

(Paragraph V.B below.)

1.

If, as a result of rework, repair or modification, the.

final acceptance inspection status is to be negated with a turnback to the contractor, the turnback shall be made in accordance with the applicable Test Instruction.

A copy of the turnback shall be given to the Le.'d P

Mechanical Quality Control Engineer prior to work being pe r fo rmed.

2.

Upon completion of the work performed during a turnback, the Quality Control Inspector shall perform an inspection of the affected system (or portion of a system), ce=po-nent, etc.

A supplement to the original Turnover agreement shall be prepared and will include a Turnover agreement check list (if applicable), punch lists, and any other app?* able doce=entation. The Equipment No./ Inspection Boundary section of the turnover Agree =ent shall clearly identify the inspection boundaries. All applicable docu-mentation shall be cade a part of the permanent quality control file by the Quality Assurance group.

B.

The following requirements apply to work performed by the contractor on punch list items and design changes:

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s-Rei. O Date:May 4,1979 V.

REWORK, REPAIR OR MODIFICATION - Continued B. - Continued

1. It shall be the responsibility of the contractor's Super-visor to notify the Lead Mechanical Quality Centrol Engineer af all work proposed to resolse punch list items reported during the inspections and all work performed per approved design changes.

2. The Quality Control Inspector shall perform an inspection of work resulting from resolutions to punch list ite=s and the approved design changes using a check list or inspection re-port as applicable.

3. All work and inspection resulting from these resolutions shall be documented and will be made part of the equipment / system file.

Inspection Reports of cleared punch list items shall be attacheli to the data package.

Check lists specially pre-pared and approved for use during inspection cf systems, com-ponents, etc. affected by design changes will also be made part of the Turn-Over data package. All applicable docu=en-tation shall be =ade a part of the permanent giality control record file by the Quality Assurance Group.

4.

If a system has be 2n turned over to Met-Ed/GFC Start-Up and there are punch list ite=s recaining open that do not affect the integrity or previous testing of the system (i.e., installation of hangers, clean-ep, painting), these may continue to be worked by the Con-tractor without a Turnback notification.

Quality Control, upon notification, shall perform an inspection of the work resulting from resoluti.ons to 5 h, b,l'IiDi

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punch list items and document the results using a checklist and/or inspection report as applicable.

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Rev. O Date: May 4, 1979 V.

REWORK, REPAIR OR FDDIFICATION - Continued B. 4. - Continued A Jupplement to the original Turn-Over shall be prepared and

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will include a Turn-Over Agreement, checklists (if applicable) and the Inspection Report (s) that indicates those punch list items that have been resolved.

If additional items are noted during the inspections that have not been previously punch listed, they shall be included in the package.

C. If the Construction turnover package includes system drawings and/

or erection drawings, the applicable Craft Su, -visor should main-tain a log of those drawings, as required.

If, as a result of re-pairs, rework, modifications, etc., revisions are made to any of these drawings, the Craft Supervisor shall notify the Lead QCE that such revisions have been made. The Lead QCE, or his desig-nate, shall review the revised drawings to determine if any por-tions of the turred over systems are affected by the drawing change. The Lead QCE or his designate shall note any such chang-es to turned over systems in his system. file log (See Attachment "E").

1. The QC inspector shall inspect the affected portion of appli.

cable component /systen, as shown on the drawing revision, and r

shall indicate inspection status and initial and date the ap-plicable drawing revision in the system file log.

2. For changes made to drawings which do not affect the turned ov-er portion of the systems, the Lead Quality Control Engineer, or his designate, shall note his review of the revised draw-ing in the system file log.

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QCP-M-012 Rev. O Date-May 4, 1979 VI.

SUBCOhTRACTORS 4

Subcontractors shall notify the cogni ant superintendent or supervisor when an item, system, etc. has been co=pleted and is ready for turnover. Af ter review of

• e turnover, the Superintendent or Supervisor shall then notify the Lead M.J.anic01 Quality Control Enginee r in writing that the item, system, etc. is ready for.inel inspection.

B.

The Lead Mechanical Quality Control Engineer shall initiate the necessary actions to perform final inspection.

VII.

QUALIFICATION

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A.

Quality Control Inspectors sho are responsible for inspections of test and checks during Pre-operational Start-Up and Operational phases of the plant shall ba qualified to ANSI-N45.2.6 for a Level I or Level II.

In addition, the Quality Control Engineers shall coet the recom= ended educa-tional and experience requirements and the level of capability for Level II or III as specified in ANSI-N45.2.6..

The capabilities and proficiency of Quality Control personnel qualified in accordance with ANSI-N45.2.6 shall be determined by suitable performance de=onstration and a ~ written or oral exanination.

Certification records, as required by ANSI-N45.2.6 for Quality Control Level personnel, shall be maintained on file.

A documented evaluation will be made at least once yearly.

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QCP-M-012 Unit No, GPU SERVICC CORPORATION Rev. 0 QUALITY CCNTROL FINAL ACCEPTANCE INSPECTION CHECK LIST Approved by:

Equipment / System Lead Q.C. Engr./Date Sub-system Nomenclature GPUSC Q.A./Date Weld Map /Insp. Boundry INSPECTION ACC REJ RE.%GKS

1. Verify that incomplete work, documentation and outstand-ing deviations have been re-solved as follows:

a. Verify that hold tags hava been cleared.

b. Verify that required out-standing documentation re-quired by bill of materials has been received.

c. Verify that all construction related inspections are com-plete.

d. Verify that installation is as per latest drawing and specification revision.

(SAMPLE)

Inspector Date

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syr-n-u16 Rev. O Date: Mcy 4, 1979 GPU SERVICE CORPORATION QUALITY CONTROL PUNCH LIST TITLE:

DRAWING NO.

SYS111M/C"B-SYS'.EM NO.

EQUIPMENT NO./ INSPECTION BOUNDARY REFERENCE SPEC. NO.

PREPARED BY:

QUALIIY CONTROL INSPECTOR DATE:

REVIEWED BY:

LEAD QUALITY CONTROL ENGINEER DATE:

DISTRIBifrION:

DATE ISSUED:

SHEET 1 0F PUNCH LIST A preliminary inspection and documentation check has been completed. The following ite=s were found to require additional work:

Item No.

Description of Item a..a y a.,

(Attach =ent "B")

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QCP-M-012 Rev. O GPU SERVICE CORPORATION Date: May 4, 1979 TURNOVER AGREEMEhT TITLE DRAWING NO.

SYSTEM /SUB-SYSTEM NO.

EQUIPMENT NO./ INSPECTION BOUNDARY REFERENCE SPEC. NO.

Quality Control has completed the applicable Final Inspection on the above equipment /

system in accordance with the attached Inspection Check List. We certify that this equip-ment / system has been built in accordance with pertinent plans and specifications, except for the incomplete items and deviations listed on the Check List.

Punch List Attached No Punch List Attached PREPARED BY:

4 QUALITY CONTROL INSPECTOR DATE INSPECTION COMPLETED:

QUALITY CONTROL ENGINEER DATE REVIEWED:

DATE LEAD QUALITY CONTROL ENGINEER The Start-Up Department accepts the above equipment / system for pre-operational testing.

We agree to abide to all Quality Control requirements specified on the Quality Ccatrol Pre-Operational Testing Check Lists and to notify the Lead Start-Up Quality Control Engineer of any impending repairs, rework or modifications to the co=ponent/syste.

ACCEP11ED BY:

MET-ED/GPU START-UP DATE ACCEPTED BY:

MET-ED QA

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(Attachment "C")

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QCP-M-012

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Rev. O GPU SERVICE CORPORATION Date: May 4, 1979 THREE MILE ISLAND NUCLEAR GENERATING STATION EQUIPMENT TURNBACK SHEET Unit No.

From:

Dept.

System:

To:

Dep t.

Date:

The following equipment is transferred for jurisdictional purposez for work to be performed as noted.

E')JIPMENT DESCRIPTION ACCEPTED BY SIGNED FOR DEPT.

FOR DEPT.

From:

Dept.

Date:

TO:

Dept.

The work as described has been completed and the equipment is transferred for jurisdictional ~

purposes.

EQUIPMENT DESCRIPTION OF WORK DWG.

REV.

DATE i

ACCEPTED BY:

SIGNED FOR:

DEPT.

FOR (Attachment ".D")

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Rev. O GPU SERVICE CORPORATION Date: May 4,1979 SYS'l?.M DRAWING REVISION LOG System No.

Inspection Inspection Required Status Dwg. No.

Rev.

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GPU SERVICE CORPORATION Rev. J Date: May 4,1979 QA/QC TRANSMllTAL FORM FOR TURNOVER A'GREEMENT TITLE DWG. NO.

SYSTEM /SUB-SYSTE NO.

EQUIPMENT NO./ INSPECTION BOUNDARY REFERENCE SPEC. NO.

in accordance with QCP-M-012, subject Turnover Agreement is being submitted to Quality Assurance for audit.

LEAD Q.C. ENGINEER /Date Subject Agreecent is being returned to Quality Control for resolution of the below listed comments and/or discrepancies.

GPUSC Q. A. ENGINEER /Date The above listed comments and/or discrepancies have been resolved and the Agreement is -

now satisfactory.

i GPUSC Q. A. ENGINEER /Date SITE Q.A. MANAGER GPUSC/Date Subject Agreement has been audited by Quality Assurance with no comments and is satis-factory.

GPUSC Q. A. ENGINEER /Date SITE Q.A. MANAGER GPUSC/Date ntqcy:p u a. u u..e )

(Attachment "F")

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